MQ Power WHISPERWATT DCA70SSJU4F Operation Manual
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MQ Power WHISPERWATT DCA70SSJU4F Operation Manual

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OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL DCA70SSJU4F
60Hz GENERATOR
(JOHN DEERE 4045HFG04 DIESEL ENGINE)
INSTRUCTION MANUAL NO. M2844300014A
Revision #5 (05/03/22)
To find the latest revision of this publication or
associated parts manual, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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  • Page 1 OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA70SSJU4F 60Hz GENERATOR (JOHN DEERE 4045HFG04 DIESEL ENGINE) INSTRUCTION MANUAL NO. M2844300014A Revision #5 (05/03/22) To find the latest revision of this publication or associated parts manual, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING PAGE 2 — DCA70SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #5 (05/03/22)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA70SSJU4F 60 Hz Generator Proposition 65 Warning ........... 2 Table Of Contents ............ 3 Safety Decals ............4 Safety Information ..........5–10 Specifications ............11 Dimensions ............12 Installation ............14–15 General Information ..........16 Major Components ..........17 Engine Control Unit (ECU) ........

  • Page 4: Safety Decals

    SAFETY DECALS SAFETY DECALS NOTICE Safety decals are attached to the generator as shown in For safety decal part numbers, refer to the associated Figure 1. Keep these safety decals clean at all times. When parts manual. the safety decals become worn or damaged, contact your nearest dealer or the Multiquip Parts Department.

  • Page 5: Safety Information

    SAFETY INFORMATION Do not operate or service the generator before reading the Potential hazards associated with the operation of this entire manual. Safety precautions should be followed at all generator will be referenced with hazard symbols which times when operating this generator. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages.
  • Page 6 „ NEVER use accessories or attachments that are not being used. The generator should be stored in a clean, dry location out of the reach of children and unauthorized recommended by MQ Power for this generator. Damage to the generator and/or injury to the user may result. personnel.
  • Page 7 SAFETY INFORMATION ENGINE SAFETY „ Operation of the generator may create sparks that can start fi res around dry vegetation. A spark arrestor DANGER may be required. The operator should contact local fi re agencies for laws or regulations relating to fi re prevention „...
  • Page 8 SAFETY INFORMATION „ State Health Safety Codes and Public Resources „ Refer to the MQ Power trailer manual for additional safety Codes specify that in certain locations, spark arresters information. must be used on internal combustion engines that use „ In order to reduce the possibility of an accident hydrocarbon fuels.
  • Page 9 SAFETY INFORMATION „ Raise and lock the trailer wheel stand in the upright „ NEVER use damaged or worn cables or cords when position when towing. connecting equipment to the generator. Inspect the insulation for cuts. „ Place chock blocks underneath the wheels to prevent rolling while parked.
  • Page 10 SAFETY INFORMATION „ ALWAYS keep the battery charged. If the battery is not Metal recycling involves the collection of metal from charged, combustible gas will build up. discarded products and its transformation into raw materials to use in manufacturing a new product. „...

  • Page 11: Specifications

    SPECIFICATIONS Table 1. Generator Specifications Model DCA70SSJU4F Type Revolving field, self-ventilated, protected type synchronous generator Armature Connection Star with Neutral Zigzag Phase 3Ø 1Ø Standby Output 62 kW (77 kVA) 44 kW Prime Output 56 kW (70 kVA) 40 kW 3Ø...

  • Page 12: Dimensions

    DIMENSIONS 6,960 lb. (3,157 kg) Figure 2. Dimensions Table 3. Dimensions Reference Reference Dimension in. (mm) Dimension in. (mm) Letter Letter 33.98 (863) 39.25 (997) 32.80 (833) 105.12 (2,670) 39.25 (997) 59.05 (1,500) 32.28 (820) 37.40 (950) PAGE 12 — DCA70SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #5 (05/03/22)
  • Page 13 NOTES DCA70SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #5 (05/03/22) — PAGE 13...

  • Page 14: Installation

    M I N 2 . 4 T . / REFERENCE NEC 250 Figure 3. Typical Generator Grounding Application NOTICE Trailer-mounted generators are the sole responsibility of MQ Power. PAGE 14 — DCA70SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #5 (05/03/22)
  • Page 15 INSTALLATION OUTDOOR INSTALLATION GENERATOR GROUNDING NOTICE Install the generator in an area that is free of debris, bystanders, and overhead obstructions. Make sure the The Occupational Safety and Health Administration generator is on secure, level ground so that it cannot slide (OSHA) and the National Electrical Code (NEC) or shift around.

  • Page 16: General Information

    Reference Table 2 for engine specifications. „ Voltmeter Change-Over Switch „ Voltage Regulator In keeping with MQ Power’s policy of constantly improving „ 3-Pole, 200-Amp Main Circuit Breaker its products, the specifications quoted herein are subject „ “Control Box” (located behind Control Panel) to change without prior notice.

  • Page 17: Major Components

    MAJOR COMPONENTS Ｕ Ｖ Ｗ Ｏ Table 4. Generator Major Components ITEM NO. DESCRIPTION Battery Assembly Oil Drain with Valve Assembly DEF Tank Assembly DEF Supply Module Assembly Fuel Tank Assembly Air Cleaner Assembly °F VOLTS INCREASE DECREASE OIL PRESS WATER TEMP BATTERY ½...

  • Page 18: Engine Control Unit (Ecu)

    ENGINE CONTROL UNIT (ECU) Series 800 Controller Engine Started RPMX10 °F INCREASE DECREASE OIL PRESS WATER TEMP SPEED ＥＣＵ Shutdown VOLTS Integrated Gauge Panel ½ ½ Check Emissions Failure °F °F Emissions Failure Pre-Alarm Regen Needed FUEL Regen Inhibit Fuel Series 800 Controller Engine Started Shutdown...

  • Page 19: Engine/Generator Control Panel

    ENGINE/GENERATOR CONTROL PANEL RPMX10 °F INCREASE DECREASE OIL PRESS WATER TEMP SPEED ＥＣＵ VOLTS Integrated Gauge Panel °F RPMX10 ½ ½ Check Emissions Failure °F °F Emissions Failure Regen Needed FUEL Regen Inhibit Fuel OIL PRESS WATER TEMP SPEED ＥＣＵ VOLTS Integrated Gauge Panel ½...

  • Page 20: Output Terminal Panel Familiarization

    OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel (Figure 8) shown below is The “Output Terminal Panel” (Figure 8) is provided with located on the right-hand side (left from the control panel) the following: of the generator.
  • Page 21 OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles Each auxiliary receptacle is protected by a 50-amp circuit breaker. These breakers are located directly above the NOTICE GFCI receptacles. Remember the load output (current) on It is recommended that the GFCI receptacles be tested both receptacles is dependent on the load requirements of when the generator is initially uncrated.
  • Page 22 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Overcurrent Relay Loads can be connected to the generator by the Output An overcurrent relay (Figure 14) is connected to the main Terminal Lugs or the convenience receptacles (Figure 13). circuit breaker. In the event of an overload, both the circuit Make sure to read the operation manual before attempting breaker and the overcurrent relay may trip.

  • Page 23: Load Application

    LOAD APPLICATION SINGLE-PHASE LOAD THREE-PHASE LOAD Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase and equipment to ensure the wattage, amperage, frequency, power use the following equation: and voltage requirements are satisfactorily supplied by the VOLTAGE ×...

  • Page 24: Powerbalance

    POWERBALANCE™ PowerBalance™ (Figure 15) is an optional load PowerBalance™ continuously monitors engine load by management solution that helps protect the engine generator sensing the engine exhaust temperature. from problems resulting from sustained low-load operations (defined as less than 30% of the generator full-load rating). POWERBALANCE™...

  • Page 25: Generator Outputs

    GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES Maximum Amps Table 8 shows the maximum amps the generator can A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using provide. DO NOT exceed the maximum amps as listed. the voltage selector switch (Figure 16).

  • Page 26: Generator Outputs/Gauge Reading

    GENERATOR OUTPUTS/GAUGE READING HOW TO READ THE AC AMMETER AC Ammeter Gauge Reading AND AC VOLTMETER GAUGES Place the AC Ammeter Change-Over Switch (Figure 20) in the U position and observe the current reading (load The AC ammeter and AC voltmeter gauges are controlled drain) on the U terminal as indicated on the AC Ammeter by the AC ammeter and AC voltmeter change-over switches.

  • Page 27: Output Terminal Panel Connections

    OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES 3. Turn the voltage regulator control knob (Figure 24) clockwise to increase voltage output, tur n Various output voltages can be obtained using the UVWO counterclockwise to decrease voltage output. Use the output terminal lugs.
  • Page 28 OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480/277V UVWO Terminal Output Voltages 1Ø-240/120V UVWO Terminal Output Voltages 1. Place the voltage selector switch in the 3Ø 480/277 1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 26. position as shown in Figure 28.

  • Page 29: Inspection/Setup

    INSPECTION/SETUP ENGINE OIL CHECK 6. Fill with recommended type oil as listed in Table 11. Maximum oil capacity is 3.88 gallons (14.7 liters). 1. To check the engine oil level, place the generator on secure, level ground with the engine stopped. 2.
  • Page 30 INSPECTION/SETUP FUEL CHECK REFUELING PROCEDURE WARNING DANGER Diesel fuel and its vapors are dangerous Fuel spillage on a hot engine can cause to your health and the surrounding a fire or explosion. If fuel spillage occurs, environment. Avoid skin contact and/or wipe up the spilled fuel completely to inhaling fumes.
  • Page 31 INSPECTION/SETUP DEF REFUELING 3. NEVER overfill the fuel tank — It is important to read the fuel gauge when filling the trailer fuel tank. DO NOT NOTICE wait for fuel to rise in the filler neck (Figure 36). ONLY fill the DEF tank with diesel exhaust fluid. Any FUEL GAUGE LOCATED other type of fluid may cause severe engine damage.
  • Page 32 INSPECTION/SETUP COOLANT Operation in Freezing Weather (ANTIFREEZE/SUMMER COOLANT/WATER) When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added. John Deere recommends antifreeze/summer coolant for use in their engines, which can be purchased in concentrate (and Table 13.
  • Page 33 INSPECTION/SETUP AIR CLEANER Battery Cable Installation ALWAYS be sure the battery cables (Figure 42) are Periodic cleaning/replacement of the air cleaner is necessary. Inspect the air cleaner (Figure 41) in accordance properly connected to the battery terminals as shown below. with the maintenance section of this manual or the John The red cable is connected to the positive terminal of the Deere Engine Owner’s Manual.
  • Page 34 INSPECTION/SETUP ALTERNATOR The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously, resulting in alternator failure. DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrosion and damage the alternator.

  • Page 35: Generator Start-Up Procedure (Manual)

    GENERATOR START-UP PROCEDURE (MANUAL) BEFORE STARTING STARTING (MANUAL) 1. Place the Auto-Off/Reset-Manual Switch in the CAUTION MANUAL position to start the engine (Figure 45). The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. AUTO MANUAL Direct exhaust away from nearby personnel. OFF/RESET WARNING Figure 45.
  • Page 36 GENERATOR START-UP PROCEDURE (MANUAL) 5. If the voltage is not within the specified tolerance, use 9. The tachometer gauge (Figure 52) will indicate the the voltage regulator control knob (Figure 48) to speed of the engine when the generator is operating. increase or decrease the desired voltage.

  • Page 37: Generator Start-Up Procedure (Auto Mode)

    GENERATOR START-UP PROCEDURE (AUTO MODE) STARTING (AUTO MODE) When starting the generator in AUTO mode use the “Manual Start-Up” procedure except where noted (see DANGER below). Before connecting this generator to any 1. Perform steps 1 through 5 in the Before Starting section building’s electrical system, a licensed as outlined in the Manual Starting Procedure.

  • Page 38: Generator Shutdown Procedure

    GENERATOR SHUTDOWN PROCEDURE EMERGENCY SHUTDOWN PROCEDURE WARNING NOTICE NEVER stop the engine suddenly except in an emergency. The Emergency Stop Pushbutton Switch should only be used to stop the engine in case of an emergency NORMAL SHUTDOWN PROCEDURE or to lock out operation during service. The emergency stop switch should NEVER be used for routine stopping To shut down the generator, use the following procedure: of the engine.

  • Page 39: Maintenance

    MAINTENANCE 500 Hrs. 10 Hrs. Table 14. Inspection/Maintenance 250 Hrs. or Every 2,500 Hrs. OTHER DAILY 12 Months Check Engine Oil and Coolant Levels Check Fuel Filter/Water Separator Bowl Check Air Cleaner/Element Clean or Replace Air Cleaner/Element Check for Leaks/Hoses/Clamps Check for Loosening of Parts Change Engine Oil and Oil Filter* Clean Unit, Inside and Outside...
  • Page 40 MAINTENANCE Primary and Secondary Air Cleaner Elements GENERAL INSPECTION Prior to each use, the generator should be cleaned and 1. Release the latches (Figure 59) that secure the cover inspected for deficiencies. Check for loose, missing or to the air cleaner body. damaged nuts, bolts or other fasteners.
  • Page 41 MAINTENANCE Air Filter Dust Indicator FILTER BODY AIR BLEEDER NOTICE (HEAD) PLUG RETAINING The air filter should not be changed until the indicator RING reads RED. Dispose of the old air filter. It may not be FUEL FILTER (CUP) cleaned or reused. DRAIN VALVE The air filter indicator (Figure 60) is attached to the air filter.
  • Page 42 MAINTENANCE FUEL FILTER ELEMENT REPLACEMENT FUEL WATER SEPARATOR SEDIMENT BOWL 1. Use a filter wrench to remove the fuel filter cup 1. Remove the sediment bowl from the fuel water (Figure 62) from the fuel filter body. separator cartridge as shown in Figure 63. FILTER BODY (HEAD) RETAINING...
  • Page 43 MAINTENANCE FUEL WATER SEPARATOR REPLACEMENT CLEANING INSIDE THE FUEL TANK 1. Use a filter wrench to remove the fuel water separator If necessary, drain the fuel inside the fuel tank completely. Using a spray washer (Figure 65) wash out any deposits cartridge (Figure 64) from the cartridge body head.
  • Page 44 MAINTENANCE DRIVE BELT (DAILY) DRAINING ENGINE OIL Drive Belt Tension 1. Run the engine until the engine coolant reaches a temperature of 140°F (60°C). Turn the engine off. A slack drive belt (Figure 66) may contribute to overheating 2. Remove the oil dipstick from its holder. or insufficient charging of the battery.
  • Page 45 MAINTENANCE ENGINE OIL FILTER REPLACEMENT DRAINING ENGINE COOLANT WARNING 1. Clean the area around the lubricating oil filter head. 2. Using an oil filter wrench (Figure 68), remove the DO NOT remove the pressure cap from the radiator engine oil filter. when the engine is hot! Wait until the coolant temperature is below 120°F (50°C) before removing the pressure cap.
  • Page 46 MAINTENANCE FLUSHING OUT THE RADIATOR TESTING THE GFCI RECEPTACLE AND REPLACING COOLANT NOTICE „ Open both cocks located at the crankcase side and at The GFCI receptacle is designed to interrupt power the lower part of the radiator and drain the coolant. Open when a ground fault exists to prevent injuries and shock the radiator cap while draining.
  • Page 47 MAINTENANCE 4. Plug a power tool into the GFCI receptacle such as an 8. If the status LED (Figure 76) is flashing (RED), DO NOT use the GFCI receptacle and replace it electric drill (Figure 74). Squeeze the ON/OFF switch on the drill and verify that the drill turns on.
  • Page 48 MAINTENANCE ENGINE BLOCK HEATER When using the generator in hot climates there is no reason to apply power to the engine block heater. However, if the AND INTERNAL BATTERY CHARGER generator will be used in cold climates it is always a good 120 VAC INPUT RECEPTACLES idea to apply power to the engine block heater at all times.
  • Page 49 MAINTENANCE EMISSION CARBON CHECK EMISSION CONTROL Deposition of carbon (soot, unburned fuel) in the exhaust The emission control system employed with the John Deere 4045HFG diesel engine consists of a Diesel Oxidation pipe line and muffler could cause not only system derates but also could lead to fires.
  • Page 50 MAINTENANCE SELECTIVE CATALYTIC REDUCTION (SCR) NOTICE Diesel engines can be run with a lean burn air-to-fuel ratio, During urea SCR regeneration, white smoke may to ensure the full combustion of soot and to prevent the be temporarily emitted from the exhaust tailpipe. This exhaust of unburnt fuel.
  • Page 51 MAINTENANCE DIESEL EXHAUST FLUID (DEF) If the diesel exhaust fluid (DEF) symbol (Figure 80) is displayed during ECU controller operation, it indicates the The amount of fluid in the DEF tank will be shown on the following: ECU Controller main screen during operation. The symbol „...
  • Page 52 MAINTENANCE INDUCEMENT When the system senses improper usage such as no supply of DEF, use of poor quality DEF, problems with DEF jets, or disconnection of sensors, a warning will be issued before the situation becomes critical. If the warnings are ignored and the unit enters intermittent operation, the emergency shutdown will activate.
  • Page 53 MAINTENANCE HOW TO ACTIVATE ESCAPE MODE 3. Press the [Program/Exit] button (Figure 83) to enter the Main Menu. If the ECU displays any messages referenced in Table 16, it may be necessary to restart via ESCAPE MODE. SPEED 0000 Starting 1.
  • Page 54 MAINTENANCE 5. Press the [SELECT] button (Figure 85) to enter the 7. Place the Auto Start/Stop Switch (Figure 87) in the “Escape Mode” menu. “Off/Reset” position. FAULT DIAGNOSTICS ABOUT UNIT USER LOGIN MANUAL AUTO ESCAPE MODE OFF/RESET (CENTER) Figure 87. Auto Off/Reset Manual Switch DOWN SELECT (Off/Reset Position) 8.
  • Page 55 MAINTENANCE PROTECTION DEVICES Place the Auto Start/Stop Switch in the “Off/Reset” position. In addition, place all circuit breakers in the OFF position. Automatic Shutdown System Before troubleshooting, allow sufficient time for adequate cooling. Before attempting to restart the generator, perform This unit is equipped with engine protection devices that an overall inspection of the generator and correct the automatically shut down the engine if any of the faults...

  • Page 56: Troubleshooting (Diagnostics)

    TROUBLESHOOTING (DIAGNOSTICS) The engine controller of this generator diagnoses problems 5. Push the Program/Exit Button on the ECU controller and select Fault Diagnostics mode. This mode (faults/errors) that arise from the engine control system and the engine itself. enables the ability to carry out the fault diagnostics as listed below: 1.

  • Page 57: Troubleshooting (Generator)

    TROUBLESHOOTING (GENERATOR) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 shown below for diagnosis of the generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 18.

  • Page 58: Troubleshooting (Engine)

    TROUBLESHOOTING (ENGINE) Troubleshooting (Engine) Symptom Possible Problem Solution No fuel reaching injection pump? Add fuel. Check entire fuel system. Defective fuel pump? Replace fuel pump. Fuel fi lter clogged? Replace fuel fi lter and clean tank. Faulty fuel supply line? Replace or repair fuel line.
  • Page 59 TROUBLESHOOTING (ENGINE) Troubleshooting (Engine) - continued Symptom Possible Problem Solution Air fi lter blocked? Clean or replace air fi lter. Low engine power output and low speed, Incorrect valve clearances? Adjust valves per engine specifi cation. black exhaust smoke. Malfunction at injector? See engine manual.

  • Page 60: Generator Wiring Diagram

    GENERATOR WIRING DIAGRAM PAGE 60 — DCA70SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #5 (05/03/22)

  • Page 61: Engine Wiring Diagram

    ENGINE WIRING DIAGRAM DCA70SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #5 (05/03/22) — PAGE 61...

  • Page 62: Battery Charger Wiring Diagram

    BATTERY CHARGER WIRING DIAGRAM BLACK 14 AWG. LINE (L)120VAC INPUT WHITE 14 AWG. NEUTRAL (N) GREEN 14 AWG. GROUND (G) TO CHASSIS GROUND GREEN 16 AWG. TO STARTER “B” TERMINAL RED 16 AWG. 120 VAC INPUT, INSERT EXTERNAL POWER CORD HERE. NOTES: NEMA 5-15, 15A, 120 VAC, P/N HBL5278C/HUBBLE RECEPTACLE.
  • Page 63 NOTES DCA70SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #5 (05/03/22) — PAGE 63...
  • Page 64 © COPYRIGHT 2022, MULTIQUIP INC. Multiquip Inc , the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

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